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1.
The thermocouple monitors the
temperature of the exhaust gases
entering the turbocharger at the
turbine housing. Installation requires
that the exhaust manifold be drilled
near the outlet of the manifold
adjacent to the turbine housing. For
this reason it is essential that the
turbocharger be removed from the
engine in order to clean out any metal
chips from drilling that could cause
turbine blade damage.
NOTE: The Cummins ISB engine uses
a divided exhaust manifold. The
thermocouple may be installed to
sample exhaust temperature in either
exhaust passage. We recommend the
rear passage (toward the firewall).
2.
Loosen the clamps that attach the
air inlet tube to the air filter housing
and to the turbocharger, and remove
the air inlet tube from the vehicle.
Remove the air filter housing from the
vehicle. This will allow easier access to
the turbocharger.
3.
Loosen the upper hose clamp on
the turbocharger oil drain-tube hose
that is located between the two
sections of the oil drain tube.
4.
Disconnect the oil supply hose
at the turbocharger. Disconnect the
compressor outlet hose that goes to
the intercooler.
5.
Disconnect the turbine outlet pipe
by loosening the V-band. Save V-band
for re-installation.
6.
Remove the turbocharger mounting
nuts/bolts and the turbocharger from
the exhaust manifold. Clean and
inspect the exhaust flange mounting
surfaces on the exhaust manifold.
Make sure the surface is clean and dry.
CAUTION: Anytime the
turbocharger is removed from
the engine, take care that no
foreign objects enter any of the
turbocharger connections on the
engine or the turbocharger. Foreign
objects entering air, exhaust, or
oil connections may cause major
damage to the engine and/or
turbocharger and is not covered
under any warranty. Cover the
open end of the intercooler pipe
with a clean rag, as this pipe is
very susceptible to foreign object
entry.
7.
Stuff clean shop towels into the
compressor outlet and inlet hoses to
prevent contamination from entering
the pipes. Cover the turbo oil drainpipe
to avoid contamination.
8.
Stuff a small clean shop towel
or rag 4 to 5 inches into the rear
exhaust manifold passage through the
turbocharger mounting flange. This
is to prevent chips from entering the
manifold while drilling and tapping.
9.
Use a
7
⁄
16
” drill, keeping the drill
perpendicular to the manifold surface
and drill through the exhaust manifold
into the rear passage as shown in
Figure 20
.
10.
Tap the drilled hole with a 1 ⁄
4
”
NPT pipe tap. Check the thread depth
as you tap by periodically removing
the tap and screwing the pipe coupling
into the tapped hole. The coupling
should thread in 3 to 3 1 ⁄
2
turns hand
tight. Do not install the probe in place
at this time.
11.
Remove all loose chips from the
exhaust manifold. A shop vacuum or
small brush will help. Now remove the
rag using a welding rod or coat hanger
bent into a hook.
Caution! Make sure rags are
removed from exhaust manifold
prior to reinstalling turbocharger!
12.
Install the thermocouple in the
manifold using anti-seize on the
threads.
Section 4
OPTIONAL THERMOCOUPLE INSTALLATION (REQUIRED FOR
OPTIONAL BANKS iQ AND ECONOMIND)